Alpha InTec 30GS and 40GS

Transcription

1 Installation and Servicing Instructions Alpha InTec 30GS and 40GS Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Combination Boilers with a Passive Flue Gas Heat Recovery Device For Technical help or for Service call... ALPHA HELPLINE Tel: website: Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN5 7RS British Gas Service Listed 005 For use with Natural Gas or Propane Gas (AS SUPPLIED) Leave these instructions with the User

2 BENCHMARK SCHEME To comply with Building Regulations Part L (Part 6 in Scotland) the boiler should be installed in accordance with the manufacturer s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Checklist at the back of these instructions Code of Practice For the installation, commissioning and servicing of domestic heating and hot water products. Benchmark places responsibilities on both manufacturers and installers*. The purpose is to ensure that customers** are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. Installers are required to carry out work in accordance with the following: Standards of Work Be competent and qualified to undertake the work required. Install, commission, service and use products in accordance with the manufacturer's instructions provided. Ensure that where there is responsibility for design work, the installation is correctly sized and fit for purpose. Meet the requirements of the appropriate Building Regulations. Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Control (LABC), prior to work commencing. Complete all relevant sections of the Benchmark Check list/service Record when carrying out commissioning or servicing of a product or system. Ensure that the product or system is left in a safe condition and, where possible, in good working order. Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work. Refer to the manufacturer's helpline where assistance is needed. Report product faults and concerns to the manufacturer in a timely manner. Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request. Give a full and clear explanation/demonstration of the product or system and its operation to the customer. Hand over the manufacturer's instructions, including the Benchmark Checklist, to the customer on completion of an installation. Obtain the customer's signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer's instructions. Advise the customer that regular product servicing is needed, in line with manufacturers' recommendations, to ensure that safety and efficiency is maintained. Respond promptly to calls from a customer following completion of their work, providing advice and assistance by phone and, if necessary, visiting the customer. Rectify any installation problems at no cost to the customer during the installer's guarantee period. * The use of the word "installer" is not limited to installation itself and covers those carrying out installation, commissioning and/or servicing of heating and hot water products, or the use of supporting products (such as water treatment or test equipment). ** Customer includes householders, landlords and tenants. The Benchmark Scheme is managed and promoted by: Heating and Hotwater Industry Council (HHIC) Camden House, Warwick Rd Kenilworth CV8 TH Telephone: info@hhic.org.uk Website: Useful contact details; Gas Safe Register Alpha Heating Innovation; General Sales Enquiries Technical Helpline Alpha InTec GS - Benchmark Scheme

3 CONTENTS Introduction Technical data General boiler information Installation Commissioning Routine servicing Component replacement Wiring diagrams Error codes and fault finding Short parts list...4 Benchmark Checklist...42 Service record...43 INTRODUCTION The Alpha InTec range of high efficiency condensing boilers are wall mounted, fan assisted room-sealed combination boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. These are combination boilers providing both central heating and domestic hot water at mains pressure. The boilers are supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. They are designed for use with a fully pumped, sealed and pressurised central heating system. GS models have an energy saving device (GasSaver), listed in the Government's SAP Appendix Q as a passive flue gas heat recovery device (PFGHRD) fitted within the boiler casing. The GasSaver recycles heat recovered from the flue exhaust gases which is used to pre-heat the incoming cold mains water supply before entering the boiler, thereby reducing gas consumption and improving domestic hot water efficiency. IMPORTANT It is the law that all gas appliances are installed by a competent person, i.e. Gas Safe registered personnel, in accordance with the following recommendations:- Current Gas Safety (Installation and Use) Regulations All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L. Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Byelaws (Scotland) Health & Safety Document No. 635 (The Electricity At Work Regulations 989) The installation should also be in accordance with the following British Standard Codes of Practice:- BS 5440: Flues BS 5449: Forced circulation hot water systems BS 5546: Installation of hot water supplies for domestic purposes BS 6700: Design, installation, testing and maintenance of services supplying water BS 6798: Installation of gas fired hot water boilers BS 689: Gas installation BS 7593: Code of Practice for treatment of water in heating systems BS 767: Requirements for electrical installations, IEE Wiring Regulations Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'. If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7. This appliance meets the requirements of IPX4D, i.e. degree of protection against moisture. This appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health). Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with. Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations. Notes:. Ensure that the Benchmark Checklist has been completed after the boiler has been installed and commissioned. 2. It is the law that all boiler installations are registered by the installer through the Gas Safe Gas Work Notification Scheme. 3. The boiler must only be used with Alpha CD condensing flue components. NOTE: All models may be supplied ready for use with Propane (LPG) - Refer to Section 2.2 for data specific to Propane versions. The boilers are designed for use with a fully pumped, sealed and pressurised heating system using only Propane gas. In addition to the regulations and requirements stated in these installation and servicing instructions, the boiler must be installed in accordance with BS 5482: - The Installation of Propane Burning Appliances in Permanent Dwellings. Installation pipes, cylinders and pressure regulators should be fitted in accordance with BS5482:. Bulk tank installations must comply with the requirements of the Home Office code of practice for the storage of liquefied petroleum gas at fixed installations. Propane boilers must not be installed in a room or internal space below ground level, e.g. in a basement or cellar, except where at least one side is open to ground level. Propane supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances in the house. The complete installation must be tested for gas soundness against leaks. Propane boilers have been tested and factory set for use with Propane, it should only be necessary to ensure the correct gas supply pressure of 37 mbar is available. Alpha InTec GS - Contents/Introduction 3

4 2 TECHNICAL DATA 2. TECHNICAL PERFORMANCE DATA - NATURAL GAS (Cat I2H 2H - G20 20 mbar) Heat input gross - DHW kw Heat input gross - CH kw Heat input net - DHW kw Heat input net - CH kw Heat output condensing (50/30 C) - CH kw Heat output non condensing (80/60 C) CH kw Heat output min. - CH kw Heat output nominal - DHW kw Heat output max. - DHW kw Gas rate at max. output m³/h Gas supply pressure mbar Max. CH temperature C Gas burner injector diameter mm Differential burner pressure - min. mbar Differential burner pressure - CH mbar Differential burner pressure - DHW mbar DHW flow rate at 35 C rise l/min DHW flow rate at 30 C rise - EN625 l/min DHW flow regulator l/min Dry NOx weight mg/kwh Dry NOx PPM NOx Class Factory set max. CO 2 (± 0.5%) CO 2 maximum - CH output % CO 2 maximum - DHW output % CO 2 minimum output % CO PPM CO weight mg/kwh Maximum CO/CO 2 Ratio SAP/SEDBUK seasonality efficiency 2005 % SAP/SEDBUK seasonality efficiency 2009 % EN3203/2 DHW efficiency % InTec 30GS InTec 40GS N/A Max. primary system pressure bar Min. primary system pressure bar Recommended system pressure - Cold bar.0.0 System pressure relief valve setting bar Expansion vessel size litres Expansion vessel charge pressure bar.0.0 Electrical power consumption - Max. Watts Electrical power consumption - Standby Watts Alpha InTec GS - Technical Data

5 2.2 TECHNICAL PERFORMANCE DATA - PROPANE GAS (Cat I3P 3P - G3-37 mbar) Heat input gross - DHW kw Heat input gross - CH kw Heat input net - DHW kw Heat input net - CH kw Heat output condensing (50/30 C) - CH kw Heat output non condensing (80/60 C) CH kw Heat output min. - CH kw Heat output nominal - DHW kw Heat output max. - DHW kw Gas rate at max. output l/h Gas supply pressure mbar Max. CH temperature C Gas burner injector diameter mm Differential burner pressure - min. mbar Differential burner pressure - CH mbar Differential burner pressure - DHW mbar DHW flow rate at 35 C rise l/min DHW flow rate at 30 C rise - EN625 l/min DHW flow regulator l/min Factory set max. CO 2 (± 0.5%) CO 2 maximum - CH output % CO 2 maximum - DHW output % CO 2 minimum output % Maximum CO/CO 2 Ratio InTec 30GS InTec 40GS PHYSICAL DATA Boiler flow and return connections mm Relief valve connection mm DHW inlet (cold) DHW outlet (hot) connections mm Gas connection diameter mm Boiler dimensions Height mm Width mm Depth mm Clearances for servicing Bottom mm Top (horizontal flue) mm Top (vertical flue) mm Sides mm Front mm Recommended hole size for flue pipe mm Boiler dry lift weight kg Boiler operating weight (full of water) approx. kg Max. total flue length Horizontal m Max. total flue length Vertical m Flue system diameter mm Factory fitted Filling loop InTec 30GS InTec 40GS /00 Yes /00 Yes Alpha InTec GS - Technical Data 5

6 2.4 FLUE LENGTHS CD Easy-Flue 500 mm with terminal and 90 bend. A CD Easy-Flue 000 mm with terminal and 90 bend is also available. CD 750 mm and 000 mm flue extensions are available. Length of Flue Required:- Rear Flue = wall thickness mm (includes terminal). Side Flue = wall thickness + distance between wall and side of boiler mm (includes terminal) Vertical Flue = distance from top of boiler side panel to required roof position minus 000 mm for vertical terminal assembly Maximum horizontal flue length = 8 m. Maximum vertical flue length including terminal is 0 m. Each additional CD 90 Bend is equivalent to.3 m of flue length. Each CD 45 Bend is equivalent to 0.9 m of flue length. The CD Vertical Flue terminal assembly is equivalent to m of flue length. 2.5 AVAILABLE PUMP HEAD FOR CENTRAL HEATING Head (metres) Flow (litres/hr) 2.6 ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed Optional integral single channel controls are available if required. Note: Only use the Alpha single channel controls. Do not fit any two channel controls. 230 V ~ 50 Hz CONNECTIONS LOW VOLTAGE CONNECTIONS ONLY Remove the link between and 2 if the (optional Climatic or RF Climatic control) optional Alpha Climatic control or 230 V room thermostat is used. Supply 230 V ~ 50 Hz Room thermostat (optional) FlowSmart Diverter valve connection (if fitted) FlowSmart NTC sensor (if fitted) External probe (optional) Alpha Climatic control (optional) Brown Blue G/Y Link (Red) L N _ + Blue Mains terminal block Brown Red Red Not Used V ~ Control connections WARNING Ensure Control wires are connected correctly - refer to the control and boiler instructions for connection details. Optional Alpha controls RF Climatic control receiver (optional) Low voltage terminal block RF Climatic control (optional) Fig. 6 Alpha InTec GS - Technical Data

7 2.7 BOILER SCHEMATIC 9 P Gas (P2) (P) (P3) Gas Condensate discharge Domestic hot water outlet Cold mains water inlet Primary Heating return Primary Heating flow Fig. 2 - Condensate trap 2 - DHW flow switch, filter and flow regulator 3 - N/A 4 - Pressure relief valve 5 - DHW temperature sensor 6 - Gas valve 7 - Gas valve outlet pressure point 8 - Venturi positive pressure point 9 - Venturi negative pressure point 0 - Fan - Venturi 2 - Injector 3 - Flame sensing electrode 4 - Air inlet pipe 5 - Condensing heat exchanger 6 - Heat exchanger thermal fuse 7 - GasSaver heat recovery unit 8 - Thermostatic mixing valve 9 - Air/flue sampling points 20 - Pressure sampling points 2 - Flue temperature sensor 22 - Primary temperature sensor 23 - Overheat thermostat 24 - Ignition electrodes 25 - Burner 26 - Gas manifold 27 - Expansion vessel 28 - Automatic air vent 29 - Pump 30 - Primary pressure switch 3 - DHW heat exchanger 32 - Diverter valve 33 - Drain point 34 - Automatic by-pass Note: The schematic diagram does not necessarily indicate the physical position of components Alpha InTec GS - Technical Data 7

8 3 GENERAL BOILER INFORMATION 3. GAS SUPPLY The meter and supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances in the house. Refer to Technical performance data in Section 2. and 2.2. The complete installation, including the meter, must be tested for gas tightness and purged as described in BS ELECTRICAL SUPPLY The boiler requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A The boiler must be earthed. There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls. This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than 0.75 mm² (24 x 0.2 mm) to BS 6500 Table 6. The boiler should be connected to a fused three pin plug and unswitched shuttered socket outlet (both complying with BS 363), or a fused double pole switch with a contact separation of at least 3 mm in both poles. Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 767). Note: If a room thermostat is fitted, it must be suitable for 230/240 V switching. 3.3 AIR SUPPLY The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cupboard or compartment. The minimum clearances for servicing must always be maintained. Note: A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for the purpose, i.e. comply with the Building Regulations. 3.4 FLUE SYSTEM The flue system must be installed in accordance with BS 5440:. For horizontal flues ensure that the Easy-Flue outer duct is installed horizontally (please note that the Easy-Flue inner duct already has a pre-determined slope towards the boiler for condensate to run back towards the boiler). When additional flue extensions are used, ensure the flue slopes downwards towards the boiler by a minimum of mm per metre of flue. It is recommended that horizontal and vertical flue assemblies should be supported approximately every.5 m with access provided to the joints. Flue components are available as follows:- CD Easy-Flue 500 mm (includes 90 bend and terminal) - Part No CD Easy-Flue 000 mm (includes 90 bend and terminal) - Part No CD 750 mm flue extension - Part No CD 000 mm flue extension - Part No CD 00 mm flue support brackets (pack of 5) - Part No CD 90 bend - Part No CD 45 bend - Part No CD Vertical flue terminal assembly. Refer to the separate installation instructions supplied with the assembly. Part No The following methods determine the correct length of flue required. For rear exit flue (including terminal) L = B mm For side exit flue (including terminal) L = B + C mm (min. side clearance required is 5 mm) For vertical flue L = H minus 000 mm for vertical terminal assembly Where L = Required flue length B = Finished wall thickness C = Distance from the inside wall to the side of the boiler H = Distance from top of boiler side panel to roof position Note:. If an extra 90 bend is used, this reduces the maximum flue length by.3 m. Each 45 bend used reduces the maximum flue length by 0.9 m. 2. Under no circumstances must the InTec GS flue length (including allowances for extra bends) exceed 8 metres horizontally and only 0 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe. 4. Further Plume management flue accessories are available - Refer to the Easy-Flue installation instructions. 8 Alpha InTec GS - General Boiler Information

9 HORIZONTAL FLUE OPTIONS - Lmax = 8 metres (245 mm length includes terminal) L = B + C mm L = B + C + E mm C B C B E B F E L = B + E + F mm + (90 bend =.3 metre) C B L = B + C mm + (2 x 45 bends =.8 metre) VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Not less than 300 mm Not less than 300 mm H H Hmax = 0 m Fig. 3 Hmax = 8.2 m Alpha InTec GS - General Boiler Information 9

10 3.5 FLUE TERMINAL LOCATION - Figs. 4 and 5 Q N O P D G J Boundary H I Fig. 4 Terminal position A Directly below an opening, air brick, windows, etc. B Below gutters, soil pipes or drain pipes C Below eaves D Below balconies E From a vertical drain pipe or soil pipe F From an internal or external corner G Above ground, roof or balcony level H From a surface or boundary facing the terminal I From a terminal facing the terminal J Above an opening, air brick, window etc. K Vertically from a terminal on the same wall L Horizontally from a terminal on the same wall M Horizontally from an opening, air brick, window etc. N Minimum protrusion through a roof O From a vertical obstruction P From an openable window Q From an adjacent vertical terminal Min. distance (mm) 300 (See Note ) 75 (See Note 3) 200 (See Note 3) 200 (See Note 3) 50 (See Note 3) 300 (See Note 2) (See Note 4) 200 mm 300 (See Note ) 500 mm 300 mm 300 mm (See Note ) 300 mm 300 mm 600 mm 600 mm Notes:. In addition, the terminal should not be nearer than 50 mm to the framework of an opening into the building, i.e. a window surround or door surround. 2. This clearance may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferable. 3. These clearances may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the condensate plume does not affect adjacent surfaces the terminal can be extended beyond gutters, pipes, eaves, balconies etc. by upto 500 mm. If the flue is extended more than 500 mm outside, it should be boxed and insulated. 4. To reduce the possibility of nuisance to neighbouring buildings etc. it is recommended the terminal should not be less than 2500 mm from car parking spaces, building boundary walls, fences etc. 5. A terminal must not be sited under a car port roof. 6. In certain weather conditions the terminal will emit a plume of steam. If possible avoid positioning the terminal where this may cause a nuisance, i.e. positions A, D, G, H, J or M. 7. The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times. 8. A terminal must not be sited below 2 m where people have access to, such as public footpaths, access routes, patios etc. However, If the terminal is fitted less than 2 m above a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. 0 Alpha InTec GS - General Boiler Information

11 Proximity of flue duct outlets to boundaries The flue duct shall be sited so that it is at least 600 mm (see Fig. 5) from the boundary line when facing it and at least 300 mm from the boundary line when running parallel to it. Boundary Boundary Building Terminal 600 mm Building 300 mm Terminal facing the boundary Terminal parallel to the boundary Terminal Boundary Adjacent building Window Building 300 mm 600 mm Terminal Boundary Building Terminal 2000 mm Terminal at an angle to the boundary Terminal facing an opening in adjacent building Fig BOILER LOCATION The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building. The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers 'Guide for Gas Installations in Timber Frame Housing', reference IGE/UP/7. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current IEE Wiring (BS 767) Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. Where a roomsealed boiler is installed in a room containing a bath or shower, it must not be possible for a person using the bath or shower to touch any electrical switch or boiler control utilising mains electricity. The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that purpose, i.e. complies with the Building Regulations and the requirements of BS If required the boiler gas and water pipework can be run up the wall behind the boiler. Refer to the wall mounting template for positions. Alpha InTec GS - General Boiler Information

12 3.7 CENTRAL HEATING SYSTEM - Fig. 6 The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS The system should be designed to operate with flow temperatures of up to 82 C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance table for guidelines. System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum water content of 80 litres (8 gal). Above 80 litres, consideration should be given to fitting an additional expansion vessel fitted in the position shown in Fig. 6. To check correct operation of the expansion vessel(s) the system pressure should not be more than 2.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:). The boiler is supplied with the following components built in:- Pressure relief valve - complying with BS 6759 and set to operate at 3 bar. The discharge pipe must be routed clear of the boiler and terminated in such a manner that it can be seen, but cannot cause injury to persons or property. Pressure gauge - To indicate the system pressure to be maintained. Expansion vessel - Conforming to BS 484 with a capacity of 8 litres and pre-charged to a pressure of 0.8 bar. By-pass - The boiler incorporates an automatic by-pass, therefore an automatic by-pass is not required for the system. Static head of system Boiler casing Automatic air vent Additional expansion vessel (if required) Filling point Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance. Heating flow Heating return System drain tap DHW outlet Mains water inlet Note: If the mains is fitted with water meter, check valves or loose jumper stop cock, then a DHW expansion device must be fitted. Fig FILLING THE CENTRAL HEATING SYSTEM - Fig. 7 The system design pressure (cold) should be set to.0 bar. This pressure is equivalent to a static head (see Fig. 6) of 0.2 metres of water. Provision must be made for filling the system. This is done by the use of a filling loop. See Fig. 7. A filling loop is supplied factory fitted to the InTec GS models. Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system may be filled via a temporary connection as shown in Fig. 7. After filling, always disconnect the flexible hose of the filling loop. All fittings used in the system must be able to withstand pressures up to 3 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained. Heating circuit return Stop valve Hose unions Double check valve assembly Test cock Filling loop temporarily connected Stop valve Mains water supply Fig. 7 2 Alpha InTec GS - General Boiler Information

13 3.9 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha InTec boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system. If a cleaning agent and inhibitor are used, they must be applied in accordance with their manufacturers instructions. Only products from Fernox and Sentinel are acceptable for use with the Alpha InTec boilers. Further information can be obtained from Fernox (Tel: ) or Sentinel (Tel: ). The system should be flushed in accordance with BS 7593 and BS The following procedures are recommended:. Installing onto a new system:- a. Fill the system, vent at high points, at pump, primary heat exchanger and radiators. b. Check for leaks. c. Drain the system. d. If required, chemically clean the system as instructed by the recommended cleaner manufacturer. Note: Ensure that the system is flushed to remove any remains of the cleaner. e. If chemical cleaner is not used to clean the system:- i) Refill the system. ii) Switch on the boiler and allow the system to heat up to the normal operating temperature. iii) Switch off the boiler and drain the system while the water is still hot. iv) Refill the system and check for leaks. f. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. 2. Installing onto an existing system, clean the system before fitting the new boiler:- a. If the old boiler is still working:- i) Switch on the boiler and allow the system to heat up to the normal operating temperature. ii) Switch off the boiler and drain the system while the water is still hot. iii) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. iv) Ensure the system is flushed to remove any remains of the cleaner. v) Fit the new boiler. b. If the old boiler is not working:- i) Drain the system. ii) Remove the old boiler. iii) Flush the system through. iv) Fit the new boiler. v) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. vi) Ensure the system is flushed to remove any remains of the cleaner and check for leaks. c. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. 3.0 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha InTec boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate. The boilers incorporate a condensate trap which has a seal of 75 mm, therefore no additional trap is required. The condensate should ideally be discharged internally into an internal waste pipe (washing machine/sink waste) or soil pipe to avoid the possible risk of freezing. The pipework must be in 22 mm pipe. External pipe runs should be avoided, but if it is necessary, the pipework should be protected from the risk of freezing with waterproof insulation and the length should be kept to a maximum of 3 m and the condensate pipework should be increased to a minimum of 32 mm diameter. Termination should be into an external gulley or soakaway as shown in Figs. 8 and 9. Note: All pipework must have a continuous fall (see Figs. 8 and 9) from the boiler and must be of an acid resistant material such as plastic waste pipe. (copper or steel is not suitable). It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements. Optional Condensate Trace Heating Kit An optional Alpha InTec trace heating kit is also available to prevent the condensate from freezing. The control of this kit works with a unique patented design using the boiler PCB to control the trace heating. The outside weather probe measures the external temperature, activating the trace heating cable only when the boiler is in operation and producing condensate. This feature together with the latest technology variable resistance heating cable ensures only a small amount of electrical energy is used. If the external temperature drops below 2 C and the boiler is on, the relay PCB is operated and voltage is supplied to the trace heating wire causing it to heat up and prevent the condensate from freezing. When the outside temperature rises to 4 C or the boiler pump stops, the trace heater is switched off. The connection of the outside weather probe supplied with this kit also enables the weather compensation feature on the boiler. Alpha InTec GS - General Boiler Information 3

14 Plastic pipe Use waterproof pipework insulation in very exposed positions Ensure pipe is adequately supported Open end of pipe diverted into gully below grid but above water level Minimum gradient 2½ Fig. 8 - External gully 22mm termination from boiler, increase to 32 mm if external Cement mortar sealing 500 mm min. O 2½ fall Ground level (either/or) 25mm 00mm plastic tube 300mm Bottom of tube sealed Soakaway depth 400mm filled with limestone chippings Two rows of 3 x 2mm holes at 25mm centres, 50mm from the bottom of the tube. Holes to face away from house. Fig. 9 - External soakaway 3. DOMESTIC HOT WATER SYSTEM The minimum flow rate needed for the flow switch and burner to operate is 2.5 litres/min. The incoming mains water pressure should be between 0.2 and 5 bar to ensure efficient operation. If the pressure is above 5 bar a pressure reducing valve must be fitted. Following Part L Building Regulations, where the mains water hardness exceeds 200 parts per million, provision should be made to treat the feed water to the hot water circuit of combination boilers to reduce the rate of accumulation of limescale. To ensure economic use, the pipe runs between the boiler and taps should be in 5 mm copper pipe and be as short as possible. Where possible the pipework should be insulated to reduce heat loss. All taps and mixing valves used with the hot water system must be suitable for operating at a mains pressure of up to 8 bar. Showers - A shower may be used with the boiler if required. If a loose or flexible head type shower is used it may require the fitting of a double check valve, to comply with Water Bye Law 7. Bidets - No anti-syphonage arrangements are necessary, provided the outlets are shrouded and it is not possible to attach a temporary hand held spray. A supply of direct mains fed hot and cold water is permitted provided the appliance is of the over-rim flushing type. Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of dirt or foreign matter entering the boiler. 4 Alpha InTec GS - General Boiler Information

15 4 INSTALLATION 4. UNPACKING. The boxes required when the boiler is installed with a horizontal flue are as follows:- Box... Cased boiler fitted with water and gas valves, union bends and washers Mounting bracket plus screws and wall plugs Condensate discharge pipe Literature pack and Wall template Box 2...CD Easy-Flue 500 mm or CD Easy-Flue 000 mm. Both include 90 bend and horizontal flue terminal Note: NOT required for vertical flue Notes: a. All flues must be suitable for InTec condensing boilers. b. CD 750 mm and 000 mm flue extensions are available, if required. 2. Unpack boiler and remove the loose items, packs and mounting bracket. Note: The boiler can be stood in an upright position, (to allow this, the union bends should be removed so that they do not protrude beneath the bottom - check this before standing the boiler upright). It is recommended that two persons lift the boiler 4.2 CLEARANCES REQUIRED - Fig mm 235 mm - Can be reduced to 50 mm when using a vertical flue 000 mm Minimum clearance of 450 mm from front of boiler 5 mm 440 mm 5 mm Boiler Minimum clearances 50 mm Fig PREPARE THE WALL - Fig.. Decide upon the position of the boiler taking into account the clearances required for servicing and the flue terminal position. 2. Tape the template to the wall (ensure it is level and the right way up) and mark the position of the holes for the boiler mounting bracket. If rear exit flue is used, mark the position of the hole for the flue. 3. Side exit flue - Continue the horizontal centre line of the flue across the wall to the side wall, then along the side wall 85 mm (ensure the lines are horizontal). This will give the position of the centre of the hole for the flue. 4. Cut the 0 mm diameter hole (or use a 07 mm core drill) in the wall for the flue. Notes:. Ensure the hole is horizontal. 2. For internal fitting of the flue, using the flue sealing collar supplied, cut a 30 mm dia. flue hole using a 27 mm core drill. 5. Drill the fixing holes (0 mm dia.) to accept the No.0 plugs supplied. Using the screws supplied, fit the mounting bracket. Ensure line is level Rear exit hole 0 mm dia. Template 45 mm Wall mounting bracket fixing holes (6 off) 85 mm Position of 0 mm hole to be cut for side exit flue Outline of boiler Fig. Alpha InTec GS - Installation 5

16 4.4 FIT THE BOILER - Refer to Fig. Lift the boiler and locate it on the mounting bracket - the boiler should be lifted by two persons. Note: When handling or lifting always use safe techniques - keep your back straight, bend your knees, don't twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. 4.5 CONNECT THE PIPEWORK - Fig. 2 There is sufficient space between the boiler chassis and the wall to run pipework vertically behind the boiler if required.. Thoroughly flush out all the water pipework. Refer to Section The valves/fittings have been factory fitted, however, check that all the connections underneath the boiler have been tightened, especially the union bends. The heating union bends supplied have been designed to enable the heating pipes to be routed from above and/or below using the same fitting. Note: When soldering to the boiler union bends, ensure the bends are not connected to the valves, otherwise the internal seals may be damaged. 3. Connect the system pipework to the boiler. One metre of copper pipe must be fitted to the boiler before connecting to any plastic pipework. Note: Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner that it may be seen, but cannot cause injury to persons or property. 4. Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe using the clip supplied. Ensure that the condensate discharge pipe is as required in Section 3.0. Filling loop Filling loop taps Cold water inlet filter A - Heating flow (22 mm) B - Hot water outlet (5 mm) C - Gas inlet (22 mm) D - Cold water mains inlet (5 mm) E - Heating return (22 mm) F - Pressure relief valve (5 mm) Condensate trap Condensate discharge pipe Heating return valve Heating flow valve Heating drain point Flow regulator and inlet filter Fig C B D F E A 5. The flue gas heat recovery unit relies on a store of water/ condensate to deliver maximum benefit, and must be primed prior to first use. When the installation of the pipework is completed, fill the unit by carefully pouring 6 litres of clean, cold water into the top central flue spigot as shown in Fig. 3. Care should be taken to ensure that no water is allowed to spill or enter the outer air duct. Note: It is normal for some water to run into the boiler heat exchanger and out the condensate drain whilst filling. 6. Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at this stage. Fig. 3 6 Alpha InTec GS - Installation

17 4.6 FIT THE FLUE - Figs. 4 and 5 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only.. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below. Note: Where the length is less than the minimum or more than the maximum, refer to Section 4.7. (B + C) Rear Flue (B) CD Easy-Flue 500 mm 000 mm B (mm) Max Min CD Easy-Flue 500 mm 000 mm B + C (mm) Max Min Side Flue Fig. 4 Fig Determine the overall length (L) of flue required, (see Fig. 6) as follows:- Rear flue L = wall thickness (B) + 05 mm Side flue L = wall thickness (B) + distance between boiler and wall (C) + 45 mm L Seal Joint with Tape Fig Adjust the telescopic section of the flue to the distance 'L', ensuring that the two labels marked 'TOP' are aligned, then seal and secure the joint between the ducts with the sealing tape supplied. Note: Always ensure that there is a minimum overlap of 25 mm when fully extending the telescopic section. 4. Pass the flue assembly through the wall (from inside or outside). Note: Internal fitting - If there is no access to make good the outside wall, locate the outside (black) flue sealing collar onto the outer duct of the flue immediately before the terminal grille onto the location provided. Push the flue assembly through the 30 mm flue hole, so that the collar completely passes through the wall. Then pull the flue assembly back into the correct position. Visually check that the collar is sealing the outside wall and that it is not restricting any of the openings of the flue terminal. Alpha InTec GS - Installation 7

18 30 mm Check collar is sealing the wall and it is not restricting any openings of the flue terminal Fig. 7 - Fitting the flue from inside 5. Position the smaller Easy-Flue 40 mm clamp (with seal) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position. Secure in position using the clamp. Ensure the clamp is located centrally over both the bend and boiler adaptor. 6. Fit the inside (white) flue sealing collar over the Easy-Flue. If it was not previously fitted, fit the outside (black) flue sealing collar onto the flue immediately before the terminal grille onto the location provided. 7. Slide the larger Easy-Flue 45 mm clamp over the outer duct and pull the flue assembly towards the bend, locating the inner duct into the seal joint on the bend. Ensure the labels marked 'TOP' are positioned at the top before securing the flue assembly to the bend with the clamp (three screws) located centrally over the joint. Note: Check the flue terminal protrudes 20 mm out of the wall and the inner duct of the terminal is positioned correctly (see Fig. 8). 8. Make good the inside wall by pushing the inside flue sealing collar upto the wall. Inner duct seal CD Easy-Flue Ensure the inner duct within the terminal is at the top. Note: The inner duct must be positioned to slope towards the boiler Terminal Flue sealing collar Inner duct Easy-Flue 45 mm clamp Elbow seal joint 90 bend Easy-Flue 40 mm clamp and seal Side of boiler Note: Ensure the outer flue duct is horizontal 85 Fig. 8 - Rear flue 4.7 REDUCING THE FLUE - Fig. 9 When the flue length required is less than the minimum stated in Section 4.6, paragraph, refer to Fig. 9. Discard the first telescopic section (not the section with the terminal) of the Easy-Flue 000 mm or 500 mm and cut to the required length. Note: Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed. Allow 20 mm 30 mm Do not cut past this point Fig. 9 8 Alpha InTec GS - Installation

19 4.8 EXTENDING THE FLUE - Fig. 20 Note: The flue assembly length must not exceed the maximum length stated, including the equivalent lengths of any extensions, bends etc. used for plume management components. InTec GS boilers must not exceed the maximum of an equivalent horizontal flue length of 8 m.. When the flue length required is more than the maximum stated in Section 4.6, paragraph, refer to the table below and Figs 4 and 5. Rear Flue length (B) Up to maximum: m Side Flue length (B + C) Up to maximum: m Comments Alpha CD 750 mm flue extension (Part No ) or 000 mm extension (Part No ) is required to extend the range of telescopic flue. Refer to Section 4.8 for instructions on how to extend the flue. Note: A 30 mm flue hole (27 mm core drill) may be required in the wall. This is when the extended flue is passed through the wall. Additional support brackets are required when extending the flue. These are available from Alpha, Part No Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct. 3. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750 or 000 mm flue extensions required. 4. Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension together with the extension clamps supplied (three screws). Ensure that the clamps are positioned centrally over the joints. Note: If it is required to cut an extension, DO NOT cut the end of the inner duct that incorporates the seal joint. Ensure the inner duct end without the seal joint is cut so that it is 20 mm longer than the outer duct. Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed. 5. Adjust the telescopic section of the Easy-Flue to the required length and secure the Easy-Flue with the sealing tape supplied. Fit the Easy-Flue to the extensions by locating the inner duct into the seal joint and secure with the clamp (three screws), ensuring it is located centrally over the joint. 6. Mark the end of the flue assembly 'TOP' where it is connected to the boiler, so that the 'TOP' of the flue terminal is aligned with the 'TOP' at the boiler end of the flue assembly. 7. Pass the complete flue assembly through the wall. 8. Position the smaller Easy-Flue 40 mm clamp (with seal) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position and secure in position. Ensure the seal is located centrally over both the bend and boiler adaptor. If the inside sealing collar (white) is being used to make good the inside wall, then it will need to be fitted before assembling the flue. 9. Slide the larger Easy-Flue 45 mm clamp (two screws) over the outer duct and pull the flue assembly towards the bend, locating the inner duct into the seal joint on the bend. Ensure the inner duct within the terminal is at the top. Note: The inner duct must be positioned to slope towards the boiler Ensure outer flue duct of Easy-Flue is horizontal Ensure the flue extension slopes 20 Extension clamp downwards towards the boiler by a CD Easy-Flue minimum of mm per metre 20 Inner seal joint Easy-Flue 45 mm clamp 90 bend Terminal Flue sealing collar Inner seal joint Flue length (L) CD Flue extension Easy-Flue 40 mm clamp and seal 45 Seal joint Front of boiler Fig Side flue Alpha InTec GS - Installation 9

20 0. Secure the flue assembly to the bend with the clamp ensuring it is positioned centrally over the joint, ensuring the 'TOP' marked on the outer duct is positioned at the top. Note: Check the flue terminal protrudes 20 mm out of the wall and that the inner duct of the terminal is positioned correctly, i.e. the inner duct within the terminal is at the top. See Fig Make good the outside wall by fitting the outside sealing collar (black) onto the location provided immediately behind the flue terminal grille. Make good the inside wall using the inside sealing collar (white) if required FIT PLUME MANAGEMENT COMPONENTS - (OPTIONAL) The following procedures detail the options for management of the exhaust flue gas/plume emitted from the terminal. a. The terminal supplied with the Easy-Flue can be altered to divert exhaust flue gas/plume at an angle. This can be achieved by simply turning the end section of the terminal to the desired angle. b. The CD Easy-Flue can be converted to allow the inner flue duct to be extended so as to position the terminal in an area where the exhaust flue gas/plume will not cause a nuisance. This can be done before or after installation of the flue, providing there is access to the terminal from outside. i. Remove the screws ( in Fig. 2) securing the terminal and remove the terminal by pulling it from the flue assembly. Remove the screw (2 in Fig. 2) securing the terminal end section and remove the end section from the terminal. ii. Locate a 93 Plume Management bend into the flue assembly and rotate it to the direction required. iii. Connect to the 93 bend the required Plume Management components as detailed and refer to Fig. 22. Notes:. The wall support brackets must be used to secure the Plume Management pipework to the wall and prevent disconnection of the 93 bend from the flue assembly or any other component. 2. Each joint must be secured with one of the screws provided to prevent accidental disconnection. 3. Ensure there is always a slight slope towards the flue assembly fitted in the wall and there is no part of the plume management pipework where condensate/rain will collect and cause a blockage or any restriction. iv. Terminate the Plume Management pipework by fitting the terminal end section (push-fit) previously removed. Refer to Fig. 22. v. The Plume Management components available for extending the inner flue duct are as follows:- Plume Management 93 bend 60 mm dia. (each 93 bend equivalent to.3 m flue length) Plume Management 45 bend 60 mm dia. (each 45 bend equivalent to 0.9 m flue length) Plume Management 000 mm extension 60 mm dia. (equivalent to m flue length) 60 mm dia. wall bracket 2 Fig Alpha InTec GS - Installation

21 Terminal end section from CD Easy-Flue Terminal end section from CD Easy-Flue Min. 400 mm C Note:. Ensure each joint is secured with the screw supplied. 2. Ensure there is always a slight slope towards the CD Easy-Flue so that there is no part of the pipework where condensate will collect. C Terminal end section from CD Easy-Flue PM length = C + (2 x 93 bend = 2.6 m) + (2 x 45 bends =.8 m) C Flue sealing collar CD Easy-Flue PM length = C + ( x 93 bend =.3 m) + (2 x 45 bends =.8 m) Ensure there is a slope of approximately 3 back towards the Easy-Flue PM length = C + (4 x 93 bend = 5.2 m) Fig. 22 Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not exceed the maximum flue length stated for each boiler, i.e. Alpha InTec GS boiler maximum equivalent flue length must not exceed 8 metres. Alpha InTec GS - Installation 2